COSMOS – E Engineers & Consultants

SIEMENS PS TOOLING PROJECT

AIN SOKHNA, EGYPT

SECTION 332630

STORM DRAINAGE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes storm drainage outside the building.

B. Related Sections include the following:

1. Division 31 Section "Earthworks" for excavating, trenching and backfilling.

2. Division 3 Section "Cast-in-Place Concrete" for cast-in-place concrete structures.

1.3 DEFINITIONS

A. The following are industry abbreviations for plastic materials:

1. UPVC: Un-Plasticized Polyvinyl chloride plastic.

2. GRP: Glass-Fiber Reinforced Plastic
3. VC: Vitrified clay

1.4 PERFORMANCE REQUIREMENTS

A. Gravity-Flow, Nonpressure-Piping Pressure Ratings: At least equal to system test pressure.

1.5 SUBMITTALS

A. Product Data: Submit manufacturer's technical product data and installation instructions
for system materials and products.

B. Shop Drawings: Include plans, elevations, details, and attachments for the following:

1. Drainage pipe network, including pipe diameters and gradients.

2. Manholes and other structures, including invert levels, frames, covers, and grates.
3. Perforated pipe trenches.

C. Coordination Drawings: Show manholes and other structures, pipe sizes, locations, and
elevations. Include details of underground structures and connections. Show other piping

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AIN SOKHNA, EGYPT

in same trench and clearances from sewerage system piping. Indicate interface and spatial
relationship between piping and proximate structures.

D. Coordination Profile Drawings: Show system piping in elevation. Draw profiles at

horizontal scale of not less than 1:500 and vertical scale of not less than 1:50. Indicate
underground structures and pipe. Show types, sizes, materials, and elevations of other
utilities crossing system piping.

E. As-Built Drawings: At project close-out, submit record drawings of installed pipework and
products, in accordance with requirements of the Specification, Division 1.

F. Maintenance Data: Submit maintenance data and parts lists for system materials and
products. Include this data, product data, Shop Drawings, and submit drawings in
maintenance manual; in accordance with requirements of the Specification, Division 1.

G. Certificate of Compliance.

H. Field Test Reports: Indicate and interpret test results for compliance with performance
requirements.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Do not store plastic pipe, and fittings in direct sunlight.

B. Protect pipe, pipe fittings, and seals from dirt and damage.

C. Handle pipes, precast concrete manholes and other structures according to the
manufacturer's written instructions.

D. Manufacturer’s recommendations on handling, repairing, laying, jointing, anchoring,

cutting and other works for pipes and fittings are to be strictly followed.

1.7 PROJECT CONDITIONS

A. Site Information: Perform site survey, research public utility records, and verify existing
utility locations.

B. Locate existing structures and piping, if any, to be closed and abandoned.

C. Existing Utilities: Do not interrupt or interfere with utilities serving facilities on the Project
site or on adjoining property unless permitted by Engineer under the following conditions
and then only after arranging to provide temporary utility services according to
requirements indicated or directed:

1. Notify the Engineer not less than 72 hours in advance of proposed utility
interruptions.
2. Do not proceed with utility interruptions without the Engineer's written permission.

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COSMOS – E Engineers & Consultants
SIEMENS PS TOOLING PROJECT
AIN SOKHNA, EGYPT

PART 2 - PRODUCTS

2.1 PIPING MATERIALS

A. Refer to Part 3 "Piping Applications" Article for applications of pipe and fitting materials.

2.2 PIPES AND FITTINGS

A. UPVC Gravity Pipe and Fittings:

1. PIPE: to BS 4460 and BS 54481 or DIN 19534 Parts 1 and 2, with standard dimension
ratio (SDR) of 41. Pipes of larger diameters than those included in BS 4660 and BS
5481 are to be DIN 19534 Parts 1 and 2.
2. UPVC FITTINGS: to be injection moulded and to same standard as UPVC pipes.
3. JOINTS: to be sealing ring type.
4. SOLVENT CEMENT: to BS 4346 Part 3.

B. GRP Sewer Pipes and Fittings:

1. Pipes and fittings to BS 5480, or AWWA C950-88.

2. Pipe and fittings shall include a corrosion resistant liner, a structural wall and a resin
rich exterior surface.
3. The liner shall have a nominal thickness of 1.0 mm. The liner surface shall be
reinforced with "C" glass. The remainder of the liner thickness shall be reinforced
with an acid resistant chopper "E" glass strand or mat.
4. The pipe structural wall shall consist of glass reinforcement, and fine silica sand, all
impregnated with resin. The fine silica sand shall be added to the structural layer to
achieve the design thickness for the required stiffness specified such that the overall
hoop flexural modulus (E) for pipe is not less than 24 GN/M2. Silica sand and filler
content shall not exceed 50%.
5. Pipes shall be provided with a resin rich outer layer reinforced with one layer of "C"
glass veil. The exterior layer shall have a minimum thickness of 0.2 mm. The resin
layer shall be rich and reinforced with one layer of C glass.
6. The resin used for the corrosion resistant liner of the pipe and fittings shall be high
grade polyester resin (isophthalic or better) type. For the structural wall and exterior
layer of the pipe a high grade isophthalic polyester resin shall be used. No dark
pigments shall be used in the pipe or fittings.
7. All glass reinforcements except for the inner and outer surfaces of the pipe and
fittings shall be of the "E" type. Surface reinforcement shall be of the "C" glass type.
8. Pipes shall be designed for a life of not less than 50 years. Contractor shall submit
calculations for initial and long term deflection with Truck loads, Buckling, Vacuum,
Pressure Class, and Strain in accordance with Appendix "A" of AWWA, C-950-88 or
equivalent. The maximum calculated long term deflection should not exceed 3%.
Copies of the design calculations shall be submitted to the Engineer for approval.

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a. Stiffness: Minimum 10,000 N/m2. Suitability of stiffness shall be verified for

the various trench and pipe laying conditions and as recommended by the
manufacturer.
b. Longitudinal Strength: To BS 5480 table 2 or ASTM D 3262 - 88 table 7.
c. Hoop Strength: To ASTM D 3517 Table 8.
d. Strain Corrosion Resistance: Tests are to be carried out as per ASTM D 3681 or
BS 5480 strain corrosion value at 50 years to equal or exceed 0.7%.
e. Markings: To BS 5480 clause 11.
f. Joints: GRP double socket couplings with rubber rings to BS EN 681: Parts 1
and 2, BS EN 682 and BS 7874. Allowable angular deflection to BS 5480 Table
3.

C. Vitrified Clay pipes shall conform to the requirements specified in:

1. PIPE AND FITTINGS: to BS 65 glazed on inside with ceramic or salt glaze of extra
strength.

2. JOINTS: to be of flexible sleeve type.

2.3 MANHOLES

A. Normal-Traffic Precast Concrete Manholes: ASTM C 478M, precast, reinforced concrete, of

depth indicated, with provision for rubber gasketed joints.

1. Diameter: 1200 mm minimum, unless otherwise indicated.

2. Ballast: Increase thickness of precast concrete sections or add concrete to base
section, as required to prevent flotation.
3. Base Section: 150 mm minimum thickness for floor slab and 100-mm minimum
thickness for walls and base riser section, and having separate base slab or base
section with integral floor.
4. Riser Sections: 100 mm minimum thickness, and lengths to provide depth indicated.
5. Top Section: Eccentric-cone type. Top of cone of size that matches grade rings.
6. Gaskets: ASTM C 443M rubber.
7. Grade Rings: Include two or three brick or reinforced-concrete rings, of 150 to 225
mm total thickness, that match 610 mm diameter frame and cover.
8. Pipe Connectors: ASTM C 923M, resilient, of size required, for each pipe connecting
to base section.

B. Heavy-Traffic Precast Concrete Manholes: ASTM C 913; designed according to ASTM C 890
for A-16, heavy-traffic, structural loading; of depth, shape, and dimensions indicated, with
provision for rubber gasketed joints.

1. Ballast: Increase thickness of one or more precast concrete sections or add concrete
to structure, as required to prevent flotation.
2. Gaskets: Rubber.
3. Grade Rings: Include two or three brick or reinforced-concrete rings, of 150 to 225
mm total thickness, that match 610 mm diameter frame and cover.
4. Pipe Connectors: ASTM C 923M, resilient, of size required, for each pipe connecting
to base section.

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C. Manhole Frames and Covers: Ductile iron to BS EN 124 or equivalent, epoxy coated, solid
top. Suitable lifting device for covers to be provided at a rate of one for every 10 covers.
Frames to be bolted to manhole to ensure proper fixity. Wording on cover is to be as
approved on Site. Types to be as follows:

1. For roadways: Class D400 heavy duty non-rock type for wheel loads up to 11.5 tons.
Minimum test load 400KN.
2. For sidewalks: Class B125, light duty. Minimum test load 125 KN.
3. Size: As indicated on the Drawings.

D. Manhole Cover Inserts: Manufactured, GRP form, of size to fit between manhole frame
and cover and designed to prevent stormwater inflow. Include handle for removal and
gasket for gastight sealing.

1. Type: Solid.

E. Step Irons shall be to BS 1247: PT1

2.4 STORMWATER INLETS

A. Gutter Inlets: Made with horizontal gutter opening, of materials and dimensions according
to utility standards. Include frames and grates.

B. Frames and Grates: Frames and grates according to utility standards:

1. Material: BS EN 124, or ASTM A 536, ductile-iron casting.

Grate Free Area: Approximately 50 percent, unless otherwise indicated.

2.5 GRATED CHANNELS/INTERCEPTORS

A. Normal-Traffic, Precast channel: ASTM C 478M, precast, reinforced concrete, of depth

indicated, with provision for rubber gasketed joints.

1. Base Section: 200 mm minimum thickness for floor slab and 200 mm minimum
thickness for walls and base riser section, and having separate base slab or base
section with integral floor.
2. Pipe Connectors: ASTM C 923M, resilient, of size required, for each pipe connecting
to base section.

B. Cast-in-Place Concrete, channel: Construct of reinforced concrete; designed according to

ASTM C 890 for heavy structural loading; of depth, shape, dimensions, and appurtenances
indicated.

1. Bottom, Walls, and Top: Reinforced concrete.

C. Grates and frames: Ductile iron to BS EN 124 or equivalent, epoxy coated, solid top.
Frames to be bolted to manhole/gully bricks to ensure proper fixity. Wording on cover is
to be as approved on Site.

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COSMOS – E Engineers & Consultants
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AIN SOKHNA, EGYPT

2.6 PERFORATED PIPE

A. PVC Pipes and Fittings for Gravity Application: AWWA C900, Class 100, or DIN 8062, Class 6
kg/cm2

1. Perforated Plastic Pipes: Subsurface drainage pipes shall be perforated plastic pipe
conforming to DIN 8051 Class 10 Kg/cm2 or equivalent. Perforations shall be circular
holes. Different filter requirements shall apply to each type of perforation.
2. Circular perforations shall be 5 mm in diameter arranged symmetrically in a
minimum of 4 rows parallel to the axis of the pipe. All rows shall be in the lower half
of the pipe but no row shall closer than 36 degrees to the invert. Perforations in
each row shall be at a maximum distance of 100 mm center to center.

2.7 CONCRETE

A. General: Reinforced cast-in-place concrete according to Division 3 Section "Cast-in-Place

Concrete.

2.8 FLAP VALVE

A. Type: To be flange mounted, designed for use on end closures to prevent entrance of
backwater. Seating plane is to have 10 deg. inclination.

B. Materials: Cast iron body and cover, bronze seat faces, bronze hinge pins and spring pins,
cast iron follow ring and plated steel ring draw bolts. Materials subject to de- zincification
or de-aluminuzation are not to be used.

C. End Connections: If flange mounted, flanges are to be to BS 4504 [or equivalent].

D. Factory Protection: Casting surfaces are to be given an initial coat of protective paint
immediately after shot blasting and a second coat on assembly. Protective coating is to be
hot applied coal tar or bitumen to BS 4164 [or equivalent] or BS 3416 [or equivalent]
respectively. Thickness of coat shall be at least 250 microns.

2.9 PROTECTIVE COATINGS

A. Protective coating for internal surfaces shall be bituminous damp-proofing as specified in

Division 7.

B. Waterproofing for external surfaces:

1. Structures above groundwater level: Waterproofing for external surfaces shall be

bituminous damp-proofing as specified in Division 7.
2. Structures below groundwater level: Waterproofing for external surfaces shall be
app-modified bituminous sheet waterproofing as specified in Division 7.

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COSMOS – E Engineers & Consultants
SIEMENS PS TOOLING PROJECT
AIN SOKHNA, EGYPT

PART 3 - EXECUTION

3.1 EARTHWORK

A. Excavating, trenching, and backfilling are specified in Division 31 Section "Earthwork."

B. Excavation of the Perforated Pipe Trench: The trench excavation should be limited to the
width and depth shown on the drawings and to the approval of the Engineer. Excavated
material should be placed away from the open trench so as not to jeopardize the stability
of the trench sidewalls. The bottom of the excavated trench shall not be loaded in a way
that causes soil compaction, and should be scarified prior to placement of sand. The sides
of the trench shall be trimmed of all large roots. The sidewalls shall be uniform with no
voids and scarified prior to backfilling. All infiltration trench facilities should be protected
during site construction and should be constructed after upstream areas have been
stabilized.

3.2 IDENTIFICATION

A. Materials and their installation are specified in Division 31 Section "Earthwork." Arrange
for installing green warning tapes directly over piping and at outside edges of underground
structures.

1. Use warning tape or detectable warning tape over ferrous piping.

2. Use detectable warning tape over nonferrous piping and over edges of underground
structures.

3.3 PIPING APPLICATIONS

A. General: Include watertight joints.

B. Refer to Part 2 of this Section for detailed specifications for pipe and fitting products listed
below. Use pipe, fittings, and joining methods according to applications indicated.

C. Gravity-Flow, Non-pressure Piping: Use the following pipe materials for each size range:

1. DN 600 and smaller: UPVC pipe and fittings; gaskets; and gasketed joints.
2. DN 600 and larger: Concrete pipe and fittings; gaskets; and gasketed joints.

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COSMOS – E Engineers & Consultants
SIEMENS PS TOOLING PROJECT
AIN SOKHNA, EGYPT

D. Perforated Pipe Trench Piping: Use the following pipe material:

1. UPVC pipe and fittings; gaskets; and gasketed joints.

3.4 INSTALLATION, GENERAL

A. General Locations and Arrangements: Drawing plans and details indicate general location
and arrangement of underground storm drainage piping. Location and arrangement of
piping layout take design considerations into account. Install piping as indicated, to extent
practical.

B. Install piping beginning at low point, true to grades and alignment indicated with unbroken
continuity of invert. Place bell ends of piping facing upstream. Install gaskets, seals,
sleeves, and couplings according to the manufacturer's written instructions for use of
lubricants, cements, and other installation requirements. Maintain swab or drag in line,
and pull past each joint as it is completed.

C. Use manholes for changes in direction, unless fittings are indicated. Use fittings for branch
connections, unless direct tap into existing sewer is indicated.

D. Install two flexible joints. Install the first joint at 1 diameter distance maximum from
outside face of manhole and the second joint at not more than the following distances
away from the first joint:

E. 1. Pipelines not exceeding 450 mm diameter: 1.0 m.

F. Install piping and connect to storm drains, of sizes and in locations indicated. Terminate
piping as indicated.

1. Install gravity-flow piping pitched down in direction of flow, at minimum slope of 1

percent, unless otherwise indicated.

G. Tunneling: Install pipe under streets or other obstructions that cannot be disturbed by
tunneling, jacking, or a combination of both.

3.5 PIPE JOINT CONSTRUCTION AND INSTALLATION

A. General: Join and install pipe and fittings according to installations indicated.

B. Refer to Division 33 Section "Piped Utilities – Basic Materials and Methods" for basic piping
joint construction and installation.

C. Join piping made of different materials or dimensions with couplings made for this
application. Use couplings that are compatible with and that fit both systems' materials
and dimensions.

D. Install with top surfaces of components, except piping, flush with finished surface.

E. Follow manufacturer's instructions regarding placement of bedding and backfilling,

cleanliness of joint surfaces, lubricant used, correct location of components, provision of

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AIN SOKHNA, EGYPT

correct gaps between end of spigot and back of socket, maximum permissible deflection
of joints for detachable couplings and flexible joints, provision of flexible joints for
connections to pipes built into structures.

3.6 MANHOLE INSTALLATION

A. General: Install manholes, complete with appurtenances and accessories indicated.

B. Set tops of frames and covers flush with finished surface of manholes that occur in
pavements. Set tops 75 mm above finished surface elsewhere, unless otherwise indicated.

C. Precast Units: The Contractor shall cast in steel watertight forms at least 3 weeks before
sections are used. The Contractor shall bed lowest unit on in situ concrete base and bed
and haunch in cement mortar. The Contractor shall liberally coat joints of units with
approved bituminous material of trowelling grade prior to fixing. The Contractor shall
ensure joints are filled solid and neatly strike off surplus compound. The Contractor shall
not disturb work for 7 days thereafter. Alternatively, the Contractor shall seal joints with
approved preformed jointing strip in accordance with manufacturer's instructions and shall
bed precast concrete cover slab on top unit in cement mortar.

D. Channels in bottom of manhole shall be smooth, semi-circular and size equal to diameter
of adjacent sewers. For straight through manholes, the Contractor shall construct channels
of half pipe sections. The Contractor shall make changes in direction of flow with smooth
curves as large as manholes permit. Changes in size and grade of channels shall be gradual
and even.

E. Benching: The Contractor shall form in sulphate resisting concrete Class 250/20 to rise
vertically from top of channels to a height not less than soffit of outlet pipe, then slope
upwards 1 in 10 to walls. Within 3 hours, the Contractor shall float with coat of sulphate
resisting cement-sand mortar 1:2 and finish smooth with steel trowel.

F. External Coating: Refer to Part 2 "Protective Coatings" for related specifications.

G. Internal Coating: Refer to Part 2 "Protective Coatings" for related specifications.

H. Step Irons: The Contractor shall cast into precast units or grout into preformed mortices.
The Contractor shall not use step irons as lifting eyes. Devices for lifting and handling shall
be provided on exterior faces.

I. Adjustment for Level: The Contractor shall build top courses of brickwork or concrete rings
after completion of surrounding levels and adjust as necessary to give accurate and even
final levels.

J. Covers and Gratings: The Contractor shall bed frame solidly in mortar and fix firmly using
fixing bolts and set cover in position to prevent twisting. The Contractor shall position
centrally over opening and level and square with surrounding finishes.

3.7 CAST IN PLACE CONCRETE

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COSMOS – E Engineers & Consultants
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A. Refer to Division 3 Section "Cast-in-Place Concrete" for formwork, reinforcement, and

concrete.

3.8 FIELD QUALITY CONTROL

A. Clear interior of piping and structures of dirt and superfluous material as work progresses.
Maintain swab or drag in piping, and pull past each joint as it is completed.

1. In large, accessible piping, brushes and brooms may be used for cleaning.
2. Place plug in end of incomplete piping at end of day and when work stops.
3. Flush piping between manholes and other structures to remove collected debris, if
required by the Engineer or authorities having jurisdiction.

B. Inspect interior of piping to determine whether line displacement or other damage has
occurred. Inspect after approximately 600 mm of backfill is in place, and again
immediately prior to Substantial Completion. Submit separate reports for each system
inspection.

C. Alignment: Tolerances are to be 6 mm in level and 25 mm in line between manholes or

access points unless otherwise specified. Where pipe is to be constructed in straight lines
between manholes or lampholes, the length will not be accepted if a light at each manhole
or lamphole cannot be seen from adjacent manholes.

D. Test new piping systems, and parts of existing systems that have been altered, extended,
or repaired, for leaks and defects as follows:

1. Field testing generally:

a. Provision of test equipment: All items for test have to be provided on site
before the test i.e. pressure gauges, instruments, water etc.
b. Carry out tests in the presence of the Engineer's Representative.
c. Test sections: Test gravity sewers in sections between manholes.
d. Test plug: Secure end of main and test plug by struts.
e. Apply pressure by manually operated test pump or, in the case of large
diameter mains, by power driven test pump, if approved.
f. Examine exposed joints and repair visible leaks.
g. Failure: should a test fail, locate leak and replace or make good defective pipe
or replace and make good faulty joint. Retest main.
h. Records: keep test records in an approved form. Hand original copy to the
Engineer immediately after completion of test.
i. Non-pressure lines not exceeding 1000 mm diameter are to be air tested
before backfilling and hydrostatic tested after backfilling.
j. Non-pressure lines over 1000 mm diameter are to be visually inspected from
the inside and tested at joints by hydraulic individual joint test.
k. Non-pressure lines: Carry out infiltration tests where crown of pipe at high
part of length under test is more than 1.2 m below water table.

2. Hydrostatic Testing of Non-pressure Pipelines:

a. Procedure is to be as described for pressure pipelines.

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b. Test pressure: 1.0 m head of water above pipe soffit at highest point and not
greater than 6 m head of water at lowest point of section under test. If
maximum head is exceeded, test section in stages.
c. Test period 30 minutes.
d. Allowable leakage: 0.50 litres/linear metre/metre diameter/30 minutes.

3. Air Testing of Pipelines:

a. Test procedure to BS EN 752: Parts 2-4.

b. Plug effectively length under test.
c. Apply pressure by approved method (i.e. hand pump) until a pressure 120 mm
head of water is indicated on a U-tube connected to the system.
d. Pressure drop: Without further pumping, pressure is not to fall by more than
25 mm in a period of 5 minutes.
e. Failure to pass the air test is not conclusive and if no leakage can be traced by
external application of soapy water to all sealing areas then an hydrostatic
test is to be carried out before final rejection.

4. Infiltration Test for Gravity Pipes:

a. Timing: Carry out test after total backfilling of length under test.
b. Plug effectively all inlets to system as directed.
c. Measure residual flow by approved method i.e. weir or other.
d. Infiltration limits: The following limits are not to be exceeded:

1) Pipelines not exceeding 700 mm: 0.02 litres/hour/100 linear

metres/mm diameter.
2) Pipelines over 700 mm: 0.03 litres/hour/100 linear metres/mm
diameter.

e. Failure: Test will be deemed to have failed if allowable infiltration water is

exceeded. Locate source of excessive infiltration by approved means i.e.
traversing light and mirrors or inflated rubber plug etc. and make good.
Repeat test until successful.

5. Visual Inspection Test:

a. Timing: Carry out test after total backfilling of length under test.
b. Limit of length to be tested at one time is three full- length pipes unless
otherwise approved.
c. Apparatus: Use rubber tyred bogies which do not damage lining of pipe and
an adequate supply of electric lamps.
d. Check joints by means of feelers to ensure rubber rings are correctly located.
e. Check pipe barrel for visible cracks.

6. Hydraulic Individual Joint Test for Pipes Exceeding 1000 mm:

a. Procedure: Carry out to BS 5886, Type 2 testing after backfilling, or equivalent.

Pressurize joint to 2 bars. Wait for 10 minutes at the end of which repressure
to 2 bars. Wait for 5 minutes. No pressure drop shall be observed at the end
of the latter period.

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b. Test pressure: 2 bar

c. Test period: 5 minutes.
d. Allowable leakage or pressure drop: None.

7. Cleaning and Inspection of sewers:

a. Cleaning: Clean pipeline of silt and debris after backfilling pipe trenches and
completing manholes, hatch boxes etc. but before surfaces are permanently
reinstated and make ready for inspection by the Engineer's Representative.
b. Inspection: Pipelines of 700 mm diameter and over are, where practicable, to
be inspected from the inside and when necessary a suitable trolley is to be
provided for this purpose.
c. Inspection: Pipelines less than 700 mm diameter and larger pipelines which
cannot be inspected from the inside, are to be inspected by passing a cylinder
of diameter 25 mm less than the internal diameter of the pipe and length not
less than the internal diameter of the pipe through each pipeline.
d. Testing of manholes: Plug manhole inlets and outlets, fill manhole with water
and allow to stand for at least 24 hours or such longer period to allow for
complete absorption. Re-top with water. Allowable leakage over 24 hours is
not to exceed 1 percent of total volume of manhole, otherwise make good
and retest.

END OF SECTION 332630

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